When setting up a solar power system, most people focus on panels and inverters, but the quality of DC cables is equally critical. These cables carry the solar-generated DC power from panels to inverters, and any compromise here can lead to energy losses, overheating, or even fire risks.
In this blog, we’ll explore the types of DC cables, compare their key properties, and explain how budget-grade cables can sabotage your solar investment.
1. Types of DC Cables in the Market
a. PVC (Polyvinyl Chloride) Insulated Cable
Use: Short runs, indoor or protected environments
Pros: Low cost, easy to install, Flexible and inexpensive
Cons: Poor UV and heat resistance
- Lifespan: 5–10 years in outdoor conditions
✔ Suitable for: Indoor or shaded cable runs
b. LSZH (Low Smoke Zero Halogen) Cables
Use: Indoor, enclosed spaces where fire safety is crucial
Pros: Emits less smoke and toxins during fire
Cons: Not UV/weather-resistant
- Life Span: 10-15 Years
Special-purpose cables, not ideal for direct solar use.
✔ Suitable for: Indoor installations with strict fire safety norms
c. XLPE (Cross-Linked Polyethylene) Cable
Use: Outdoor and underground wiring
Pros: Better thermal, mechanical strength and weather resistance and UV resistance than PVC
Cons: Less flexible
Lifespan: 15–20 years
✔ Suitable for: Outdoor use and underground wiring. Moderate performance, suitable for medium-budget solar setups.
d. EB-XLPE (Electron Beam Cross-linked) DC Cables
Use: Direct panel-to-inverter runs in harsh climates.
Pros: Cross-linking done with electron beams for uniformity. High heat tolerance, UV, ozone, and weather resistant. Excellent thermal stability, UV resistance, and lifespan
Cons: Slightly more expensive
Lifespan: 25–30 years
✔Best choice for long-term, high-performance solar plants.
📊 Comparative Table of Key Properties
| Property | PVC | LSZH | XLPE | EB-XLPE |
|---|---|---|---|---|
| Thermal Resistance | Up to 70°C | Up to 90°C | Up to 90°C | Up to 120°C |
| UV Resistance | ❌ Low | ❌ Poor | ✅ Medium | ✅✅ Excellent |
| Moisture Resistance | ✅ Good | ✅ Good | ✅ Good | ✅✅ Excellent |
| Chemical Resistance | ✅ Medium | ✅ Good | ✅ Good | ✅✅ Excellent |
| Flexibility | ✅ High | ✅ Medium | ✅ Medium | ⚠️ Lower |
| Lifespan (Outdoor) | 5–10 years | 10–15 years | 15–20 years | 25–30 years |
| Use in Solar | ⚠️ Limited | ❌ Indoor only | ✅ Moderate | ✅✅ Ideal |
✅ Which is the Best DC Cable for Solar?
🏆 Winner: EB-XLPE, Certified Solar DC Cables
Withstand high temperatures (120°C+)
Long lifespan (25–30 years)
Maximum UV, ozone, and water resistance
Low power losses
Safety assured even in extreme weather
⚠️ The Risk of Low-Quality Cables: What Budget Vendors Don’t Tell You
Many vendors in the market cut costs by compromising on cable quality. Since many users are not aware they put any of the above low quality cables.
Apart from this there can be few other reasons how they curtail costs :
🔻 1. Inferior Conductor Quality
Use of recycled or impure copper
Increases electrical resistance and heat generation
Reduces energy efficiency and lifespan
🔻 2. Fake Insulation Claims
Label as XLPE but use PVC
Cracks and degrades in a few years under sun/heat
🔻 3. Misleading Certifications
Fake TÜV or EN labels on non-compliant cables
No testing or international standard compliance
🔥 Consequences:
Lower solar output (2–5% drop)
Risk of cable failure, fire, inverter damage
Higher maintenance and replacement cost
💡 Expert Tip: How to Identify Good Quality DC Cable
Check Conductor: 99.9% pure copper (tinned if possible)
Insulation: EB-XLPE or double XLPE (not PVC)
Certifications: Real TÜV/EN/IEC markings, batch tested
Brand Reputation: Stick to trusted manufacturers
🧾 Conclusion
While the initial cost of a premium DC cable may be higher, it pays off in terms of efficiency, safety, and lifespan. If you’re investing in a solar plant expected to run for 25+ years, don’t let poor cabling be the weakest link.
🚫 Say no to budget traps.
✅ Say yes to long-term performance.
